Sensor for monitoring rheologically complex flows

ABSTRACT

Flow sensors, systems, and methods for continuous in situ monitoring of a rheologically complex fluid flow within a vessel, such as particulate and multiphase media for ascertaining certain fluid flow parameters, such as flow rate, dynamic viscosity, fluid density, fluid temperature, particle density and particle mass, from flow sensor measurements. The system involves a fluid flow sensor having a body member with internalized strain gauges configured to measure the deformation of certain segments of the body member. Based, at least in part, on these deformation measurements, the system is used to compute the fluid flow parameters.

STATEMENT OF RELATED APPLICATIONS

This patent application claims priority on and the benefit of U.S.provisional patent application No. 61/901,738 having a filing date of 8Nov. 2013.

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention is directed generally to the field of flowsensors; specifically, to devices, systems and methods for continuous insitu monitoring of a rheologically complex fluid flow within a vessel(e.g., particulate and multiphase media). The present invention isfunctional to ascertain certain fluid flow parameters, such as flowrate, dynamic viscosity, fluid density, fluid temperature, particledensity and particle mass, from flow sensor measurements.

2. Prior Art

In many engineering applications that deal with fluid flows,ascertaining certain fluid flow parameters from sensor measurements isfundamental. Examples of applications that deal with fluid flows includechemical processing and piping systems, food processing systems and oilpipelines. Fluid flows in such applications are typically rheologicallycomplex (i.e., multiphase, elastic, shear thinning, fibrous, particulateand highly viscous) and/or chemically aggressive.

For example, the high shear wet granulation process widely used in thepharmaceutical industry involves a rheologically complex fluid flow.Because in-line control of the properties of the particulate fluid iscrucial for producing a wet mass with specific desired characteristics,the wet granulation process depends on the accurate and precisecomputation of certain particulate fluid flow parameters.

Another example is related to the biotechnology industry. In certainbiotechnology processes, cell culture techniques are leveraged toproduce/manufacture therapeutic proteins and antibodies. An efficientand effective process analytical technology (PAT), based on reliablefluid flow sensor measurements, helps monitor cell growth inbioreactors, improves the throughput of the protein production and,therefore, reduces the cost of the drug.

Another example is related to lubricant, paint, ink or food productionwhere the viscosity of the finished product affects product quality.Because most of these fluids are non-Newtonian and have viscosities thatvary with the fluid flow velocity, dynamic in-line control of fluidviscosity is fundamental. Based on reliable fluid flow sensormeasurements, the dynamic in-line control not only helps produce a finalproduct with the correct properties but also increases the lifetime ofthe processing equipment. For example, if the viscosity of an ink flowfalls outside the acceptable range, the dynamic in-line control canblock valves and presses in the processing equipment. In the oiltransportation industry, the presence of high viscosity phases (i.e.,slugs) may affect the lifetime of the construction component.

Existing devices, systems and methods for ascertaining certain fluidflow parameters from in-line sensor measurements can be generallyseparated in two categories: non-intrusive and intrusive. Thenon-intrusive category may involve fluid flow interrogation with eitherelectromagnetic or acoustic waves. The intrusive category may involvemeasuring devices/sensors in direct contact with a fluid flow such thatthe physical effect of the fluid flow on the device/sensor is leveragedto ascertain certain fluid flow parameters.

For example, prior art non-intrusive optical devices, systems andmethods are capable of ascertaining certain fluid flow parameters fromtransparent fluids such as water and clear oils. They typically functionby transmitting their optical signal through the window of a fluid flowvessel; however, in particulate and complex flows, the optical signal isscattered or absorbed by a thin layer of solid matter that is typicallydeposited on the surface of the window. Cleaning the window withoutinterrupting the process significantly complicates the technology andrisks contamination of the fluid.

Prior art non-intrusive acoustic devices, systems and methods aregenerally considered better suited for complex fluid flows but they alsosuffer from certain significant deficiencies. Many do not provide thedesired measurement sensitivity for complex particulate fluid flowsbecause the acoustic waves are scattered by the particles and/or theacoustic waves are reflected by the structural elements of the fluidflow vessel and/or sensor.

Prior art intrusive devices, systems and methods typically employ asensor element directly contacting the fluid flow and comprising movingparts, e.g., a rotational meter, a turbine/propeller, a moveable vane, amechanical oscillator, or a deformable diaphragm. These also suffer fromsignificant deficiencies, especially in particulate and complex fluidflows, because solid matter deposits on the moving parts/jointsrendering them inoperable. It is difficult and time-consuming to cleanmoving parts, and it also risks contamination of the fluid. Suchmaintenance procedures may also require interruption of the process,which may not be acceptable/practical for the specific engineeringapplication. In addition, the moving parts introduce a risk ofmechanical failure.

Vibrational viscometers are a popular prior art example in the intrusivecategory. A vibrational viscometer is a surface loaded system thatresponds to a thin layer of fluid surrounding an oscillating probe.Measurements by the vibrational viscometer depend on the surroundingfluid dampening the probe's vibration in proportion to the fluid'sviscosity and density. Vibrational viscometers provide a sensitivemeasurement in many fluids but they often fail in particulate andmulti-phase flows where deposition of the material on the probe surfacechanges the mechanical characteristics of the probe. Vibrationalviscometers also have a relatively slow response time (e.g., severalseconds) and are highly sensitive to external vibrations that can skewthe measurements.

Target flow meters are another popular prior art example in theintrusive category. They operate on the principle that the amount offorce generated by a fluid flow when passing a target (typically a disc)is related to the fluid flow velocity, density and viscosity. Therefore,most common target flow meters employ a target whose surface is orientedperpendicular to the direction of the fluid flow. The target typicallyis mounted to a stalk, and the stalk is generally affixed to a bendablebalance beam configured to deflect/bend under the influence of the fluidflow. Strain gauges affixed to the balance beam, exposed to the fluidand/or recessed within a chamber, measure the degree of deflection/bendof the balance beam. Target flow meters have no moving parts, only abending beam, and require minimal maintenance.

Prior art target flow meters, however, suffer from significantdeficiencies. First, target flow meters have a very low sensitivitybecause of their inherent design, which must balance the need for atarget with sufficient surface area with the need for a target flowmeter that does not interfere with the fluid flow. Second, if the fluidflow is complex, viscous and/or particulate, particles in the fluid flowwill accumulate on the target and skew the measurements. Third, thestrain gauges and/or their protective means serve as a trap forparticles and high viscosity components in a complex fluid flow, whichalters the deflection/bend of the balance beam and skews themeasurements.

For example, U.S. Pat. No. 6,253,625 issued on Jul. 3, 2001 to Samuelsonet al. describes a target flow meter with a bendable stalk wherein thestrain gauges are attached to the outside surface of the stalk. Thestrain gauges are, therefore, immersed in the fluid flow. To partiallyprotect the strain gauges, the strain gauges are covered. Unfortunately,the cover creates a trap for fluid flow particles and high viscositycomponents in the complex fluid flow.

“The Design of a New Flow Meter for Pipes Based on the Drag ForceExerted on a Cylinder in Cross Flow” by C. Ruppel et al. (Transactionsof the ASME, Vol. 126, July 2004, pp. 658-664) describes a device thatconsists of a flexible cylindrical beam mounted radially across a pipe.The reference describes that a load cell placed in a recess in the pipewall measures the bending of the cylindrical beam by a fluid flow in thepipe. This approach eliminates the target by replacing it with aflexible cylindrical beam and requires that the cylindrical beamtraverse the pipe. As in the previous example, the junction between thecylindrical beam and the pipe functions as a trap for particles and highviscosity components in a complex fluid flow. Moreover, becausesignificant problems exist with sealing the force-sensing elements andelectrical connections from the effects of the fluid flow, these devicesexperience a shortened lifespan. This is especially true in chemicallyaggressive and complex fluid flows.

U.S. Pat. No. 7,127,953 B1 issued on Oct. 31, 2006 to Yowell et al.describes a target flow meter with a rigid stalk attached to a flexiblesupport base (which, therefore, constitutes a membrane). The straingauges are attached to the surface of the membrane that is not exposedto the fluid flow. The movement of the rigid stalk is translated to themembrane and the deformation of the membrane is measured by the straingauges. While this design may eliminate the disadvantage of the straingauges being directly affected by the fluid flow, it introduces a newdisadvantage: the deformation of the membrane is caused by both the dragof the fluid flow on the stalk and the fluid flow pressure.

Accordingly, there is a need for improved devices, systems, and methodsfor continuous in situ monitoring of a rheologically complex fluid flowwithin a vessel. Robust and reliable fluid flow sensors that are notsusceptible to the above described deficiencies result in reducedmaintenance costs, increased component service life and saferoperations. It is to these needs, among others, that the presentinvention is directed.

BRIEF SUMMARY OF THE INVENTION

Briefly, the present invention is a system for continuous in situmonitoring of a fluid flow within a vessel. The system comprises asensor package. The sensor package comprises a sensor. The sensorcomprises a body member and a first strain gauge. The body member has aninternal cavity such that the body member comprises a first externalsurface segment and a first internal surface segment. The body member isconfigured to extend into a fluid flow such that the internal cavity isisolated from the fluid flow and the first external surface segment isin contact with the fluid flow. The first external surface segment andthe first internal surface segment each, respectively, are configured todeform based, at least in part, on the drag of the fluid flow. Thesystem is such that the first internal surface segment translates thedeformation of the first external surface segment. The first straingauge is positioned in the cavity of the body member and configured tomeasure the deformation of the first internal surface segment. The firststrain gauge is also configured to communicate a deformation measurementof the first internal surface segment.

The present invention also is a system for continuous in situ monitoringof a fluid flow within a vessel such that the first internal surfacesegment defines a portion of the body member at which the drag of thefluid flow produces a maximum deformation in the body member.

The present invention also is a system for continuous in situ monitoringof a fluid flow within a vessel such that the sensor package isconfigured to analyze the deformation measurement of the first internalsurface segment and compute a fluid flow parameter based, at least inpart, on the deformation measurement of the first internal surfacesegment.

The present invention also is a system for continuous in situ monitoringof a fluid flow within a vessel such that the computable fluid flowparameter is a force, a temperature, a velocity, a flow rate, aviscosity, and/or a density of the fluid flow.

The present invention also is a system for continuous in situ monitoringof a fluid flow within a vessel such that if the fluid flow is aparticulate fluid then the computable fluid flow parameter is at leastone from a group consisting of a mass and a density of a particle in thefluid flow.

The present invention also is a system for continuous in situ monitoringof a fluid flow within a vessel such that the first strain gauge is anoptical strain gauge, an electrical resistive strain gauge, and/or asemiconductor strain gauge.

The present invention also is a system for continuous in situ monitoringof a fluid flow within a vessel such that the body member is sphericaland/or cylindrical.

The present invention also is a system for continuous in situ monitoringof a fluid flow within a vessel. The system comprises a sensor and aninterrogator. The sensor comprises a body member and a first opticalstrain gauge. The body member has an internal cavity such that the bodymember comprises a first external surface segment and a first internalsurface segment. The body member is configured to extend into a fluidflow such that the internal cavity is isolated from the fluid flow andthe first external surface segment is in contact with the fluid flow.The first external surface segment and the first internal surfacesegment are each, respectively, configured to deform based, at least inpart, on the drag of the fluid flow. The body member is such that thefirst internal surface segment translates the deformation of the firstexternal surface segment. The first optical strain gauge is positionedin the cavity of the body member. The first optical strain gauge isconfigured to measure the deformation of the first internal surfacesegment. The first optical strain gauge is also configured tocommunicate the deformation measurement of the first internal surfacesegment via an optical signal. The interrogator is communicativelycoupled to the first optical strain gauge. The interrogator isconfigured to receive an optical signal communicated by the opticalstrain gauge and communicate the deformation measurement of the firstinternal surface segment.

The present invention also is a system for continuous in situ monitoringof a fluid flow within a vessel additionally comprising a controllercommunicatively coupled with the interrogator. The controller isconfigured to receive the deformation measurement of the first internalsurface segment from the interrogator. The controller also is configuredto analyze the deformation measurement of the first internal surfacesegment. The controller is configured to compute a fluid flow parameterbased, at least in part, on the deformation measurement of the firstinternal surface segment.

The present invention also is a system for continuous in situ monitoringof a fluid flow such that the body member additionally comprises asecond external surface segment, a second internal surface segment, anda second strain gauge. The second external surface segment and thesecond internal surface segment are each, respectively, configured todeform based, at least in part, on the drag of the fluid flow. Thesecond internal surface segment is such that it translates thedeformation of the second external surface segment. The second and thefirst internal surface segments are aligned by a first plane. The secondstrain gauge is configured to measure the deformation of the secondinternal surface segment.

The present invention also is a system for continuous in situ monitoringof a fluid flow such that the body member additionally comprises a thirdand a fourth external surface segment, a third and a fourth internalsurface segment, and a third and fourth strain gauge. The third and thefourth external surface segments and the third and the fourth internalsurface segments are each, respectively, configured to deform based, atleast in part, on the drag of the fluid flow. The third internal surfacesegment translates the deformation of the third external surfacesegment. The fourth internal surface segment translates the deformationof the fourth external surface segment. The third and the fourthinternal surface segment are aligned by a second plane. The first andthe second planes intersect and define an angle. The third strain gaugeis configured to measure the deformation of the third internal surfacesegment and communicate a deformation measurement of the third internalsurface segment. The fourth strain gauge is configured to measure thedeformation of the fourth internal surface segment and communicate adeformation measurement of the fourth internal surface segment.

The present invention also is a system for continuous in situ monitoringof a fluid flow such that the sensor package is configured to analyzethe deformation measurements of the first, the second, the third, andthe fourth internal surface segments. The system also is configured tocompute a fluid flow parameter based, at least in part, on thedeformation measurements of the first, the second, the third, and thefourth internal surface segments and the angle defined by the first andthe second plane.

The present invention also is a system for continuous in situ monitoringof a fluid flow such that the angle defined by the first and the secondplane is 90.0 degrees.

The present invention also is a method for continuous in situ monitoringof a fluid flow involving extending a sensor, at least partially, into afluid flow within a vessel. The method also involves detecting, by thefirst strain gauge, a deformation of the first internal surface segment.The method also involves transmitting, by the first strain gauge, adeformation measurement of the first internal surface segment. Themethod also involves analyzing the deformation measurement of the firstinternal surface segment. The method also involves computing a fluidflow parameter based, at least in part, on the deformation measurementof the first internal surface segment.

The present invention also is a method for continuous in situ monitoringof a fluid flow additionally involving modifying the fluid flow.

The present invention also is a method for continuous in situ monitoringof a fluid flow additionally involving detecting, by the second straingauge, a deformation of the second internal surface segment. The methodalso involves detecting, by the third strain gauge, a deformation of thethird internal surface segment. The method also involves detecting, bythe fourth strain gauge, a deformation of the fourth internal surfacesegment. The method also involves communicating a deformationmeasurement of the first, the second, the third, and the fourth internalsurface segment. The method also involves analyzing the deformationmeasurement of the second, the third, and the fourth internal surfacesegment. The method also involves comparing the deformation measurementsof the first and the second internal surface segment. The method alsoinvolves comparing the deformation measurements of the third and thefourth internal surface segment.

The present invention also is a method for continuous in situ monitoringof a fluid flow additionally involving calculating a difference betweenthe deformation measurements of the first and the second internalsurface segment. The method also involves calculating a differencebetween the deformation measurements of the third and the fourthinternal surface segment. The method also involves computing the fluidflow parameter, based at least in part, on the difference between thedeformation measurements of the first and the second internal surfacesegment and the difference between the deformation measurements of thethird and the fourth internal surface segment.

The present invention also is a method for continuous in situ monitoringof a fluid flow additionally involving calculating a first vectorcomponent of the fluid flow parameter based, at least in part, on theangle defined by the first and the second plane and the deformationmeasurements of the first and the second internal surface segment. Themethod also involves calculating a second vector component of the fluidflow parameter based, at least in part, on the angle defined by thefirst and the second plane and the deformation measurements of the thirdand the fourth internal surface segment.

The present invention also is a method for continuous in situ monitoringof a fluid flow additionally involving computing the differentialsignal, from the first and the second strain gauge, based, at least inpart, on the difference between the deformation measurements of thefirst and the second internal surface segment. The method also involvescomputing the average signal, from the first and the second straingauge, based, at least in part, on the difference between thedeformation measurements of the first and the second internal surfacesegment. The method also involves computing the deformation of the firstsurface segment that is due to the drag of the fluid flow relative tothe thermal expansion of the first internal surface segment.

The present invention also is a method for continuous in situ monitoringof a fluid flow additionally involving detecting, by a reference sensor,the temperature of the fluid flow. The method also involvestransmitting, by the reference sensor, a temperature measurement of thefluid flow. The method also involves computing the thermal expansion ofthe first internal surface segment that is due to the temperature of thefluid flow relative to the drag of the fluid flow.

These features, and other features and advantages of the presentinvention will become more apparent to those of ordinary skill in therelevant art when the following detailed description of the preferredembodiments is read in conjunction with the appended drawings in whichlike reference numerals represent like components throughout the severalviews.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a high level functional block diagram illustrating anexemplary architecture of a system for continuous in situ monitoring ofa fluid flow.

FIG. 2A is a cross-sectional view of one embodiment of a spherical fluidflow sensor; specifically, an undeformed fluid flow sensor.

FIG. 2B is a cross-sectional view of one embodiment of a spherical fluidflow sensor; specifically, a deformed fluid flow sensor.

FIG. 3A is a cross-sectional view of one embodiment of a cylindricalfluid flow sensor; specifically, an undeformed fluid flow sensor.

FIG. 3B is a cross-sectional view of one embodiment of a cylindricalfluid flow sensor; specifically, a deformed fluid flow sensor.

FIG. 4 is a graphical representation of the dependence of the dragcoefficient on Reynolds number for a cylindrical fluid flow sensor in afluid flow.

FIG. 5 is a cross-sectional view of one embodiment of a body member of afluid flow sensor; specifically, a deformed fluid flow sensor.

FIG. 6 is a graphical presentation of a fluid flow's force over time ascomputed by a system based, at least in part, on the deformationmeasurement signals from a fluid flow sensor.

FIG. 7 is a top cross-sectional view of the body member along line 7′-7′of FIGS. 3A-3B.

FIG. 8 is side cross-sectional view of one embodiment of a plurality ofdeformed cylindrical fluid flow sensors.

FIG. 9 is a high level functional block diagram of a fluid flow forcemeasurement system for monitoring and control of an industrial process.

FIG. 10 is a logical flowchart illustrating a method of continuous insitu monitoring of a fluid flow within a vessel.

FIG. 11 is a logical flowchart illustrating a method of continuous insitu monitoring of a fluid flow within a vessel.

FIG. 12 is a logical flowchart illustrating a method of continuous insitu monitoring of a fluid flow within a vessel.

FIG. 13 is a schematic diagram illustrating an exemplary softwarearchitecture 1000 for devices, systems, and method of continuous in situmonitoring of a fluid flow within a vessel.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Aspects, features and advantages of several exemplary embodiments ofsystems and methods for continuous in situ monitoring of a fluid flowwithin a vessel are described. The systems and method will become betterunderstood with regard to the following description in connection withthe accompanying drawings. It is apparent to one having ordinary skillin the art that the described embodiments provided herein areillustrative only and not limiting, having been presented by way ofexample only.

As used in this description, the terms “component,” “database,”“module,” “system,” and the like are intended to refer to acomputer-related entity, either hardware, firmware, a combination ofhardware and software, software, or software in execution. For example,a module may be, but is not limited to being, a sensor, a processrunning on a processor, a processor, an object, an executable, a threadof execution, a program, and/or a computer. By way of illustration, bothan application running on a sensor package and the sensor package may bea system.

Certain embodiments of systems and methods for continuous in situmonitoring of a fluid flow within a vessel involve a sensor. Embodimentsof the sensor may provide a base element, adapted for fastening with astructural component (e.g., the internal walls of a vessel), and aflexible hollow body member. The hollow body member is coupled to thebase element directly or indirectly via a stalk. The outer surface ofthe hollow flexible member is configured to be extended and brought intocontact with a fluid flow. A plurality of strain gauges affixed to theinner wall surface of the hollow body member measure/monitor adeformation (e.g., bending, stretching, compressing) of an internal wallsegment of the hollow body member.

The undeformed geometry/shape/configuration of the hollow body member isa hollow sphere, a hollow cylinder, and/or a combination of various 3Dshapes having streamlined geometries relative to the fluid flow. Theinner surface of the hollow body member is isolated from the fluid flow.The outer surface of the hollow body member, exposed to the fluid flow,are composed and configured to withstand the chemical effects of thefluid and do not contaminate the fluid. The outer surface material isstainless steel; however, various materials and/or surfacelinings/treatments known to one having ordinary skill in the art are orcan be employed, e.g., Teflon® brand of synthetic polymer, plastics,polymers, organic compounds, and/or hydrophobic/hydrophilic layers.

The sensor is functional with a computation module to process thedeformation measurements (related to a change in morphology of thehollow body member) and compute fluid flow parameters (related to thedrag force of the fluid flow that changes the morphology of the hollowbody member). Exemplary parameters of the fluid flow are the flow rate,the velocity, the viscosity, the density and the temperature.

The drag force exerted by the fluid on the hollow body member causesdeformation of the geometry/shape/configuration of the hollow bodymember. For an example, a spherical hollow body member changesmorphology to a droplet shape elongated downstream. For another example,a cylindrical hollow cylinder extended across the fluid flow bends sothat the downstream wall of the cylinder undergoes compression(reduction in its length) and the upstream wall stretches (increases itslength).

The deformation of the hollow body member's walls are monitored by anyconventional sensing technique(s), e.g., optical, electrical resistive,or semiconductor strain gauge techniques. An internal surface segment ofthe hollow body member is monitored by fiber optic-based intrinsicoptical resonance techniques such as Fiber Bragg Grating (FBG) straingauges and/or Whispering Gallery Mode (WGM) stress gauges for adeformation. The sensor has at least one pair of FBG strain gaugesaffixed to the inner surface of the hollow body member for the purposeof monitoring two separate but related internal surface segments.

The sensor is applicable in a variety of open and closed systems thatinclude process systems, e.g., chemical and biological process systems,water pipeline systems, tanks and reactor vessels, broad range pipingand conduit systems (water, fuel, oil, etc.), particles (powders), andmultiphase (mixtures of liquid, gas, and solid phases) fluid flows. Thesensor is applicable to many processes, including, for example,industrial chemical, water, electric power generation, pulp and paper,heat exchanger, incinerator, and fossil fuel applications.

When not extended into a fluid flow, the sensor is in its undeformedstate and a stress gauge records a deformation measurement of the firstmechanical state of the hollow body member at a particular inner surfacesegment. When extended into a fluid flow, the sensor is in a deformedstate and a stress gauge records a deformation measurement of the secondmechanical state of the hollow body member at the particular innersurface segment. The difference between the deformation measurements istherefore indicative of the physical effects on the hollow member by thedrag of the fluid flow.

The measurement range and sensitivity of the sensor to the fluid flowdrag force is customizable based, at least in part, on the undeformedgeometry of the hollow body member, the composition and physicalproperties of the materials of the hollow body member, and the surfacetexture/pattern/configuration of the external surface of the hollow bodymember. For a spherical hollow body member, customization is based, atleast in part, on variations in the outer and inner diameter of theexternal and internal surfaces. For a cylindrical hollow body member,customization is based, at least in part, on variations in the length ofthe hollow body member, and variations in the outer and inner diameterof the external and internal surfaces. Customization also is based onvariations in the density and the Young's modulus of the materials ofthe hollow body member, and variations in thetexture/pattern/configuration of the external surface of the hollow bodymember. Furthermore, customization also is based on dynamic control ofthe elastic properties of the flexible hollow member, e.g., the sensorbeing filled with a gas, a liquid, a plasma, a silicon, or an oil.

The sensor provides minimal intrusion to the fluid flow. The sensor alsodoes not have moving parts or cavities along the outer surface of thehollow body member wherein particles and viscous components of fluidflow would accumulate. Furthermore, the sensor's stress gauges and othercircuitry/wiring/means of communicatively coupling areisolated/protected from direct exposure to the fluid flow by beingpositioned within the internal cavity of the hollow body member.

Certain embodiments of systems and methods for continuous in situmonitoring of a fluid flow within a vessel are directed towards asensor, as described above and further described herein, (also known asa fluid flow sensor) in a system. The fluid flow sensor is configured toat least take deformation measurements of an internal surface segmentalong the inner surface of the cavity within a body member.

A portion of the system is placed proximate to a vessel with a fluidflow, with the sensor being extended, at least partially, into the fluidflow from this portion. The portion also may include a computationalmodule and a monitoring module that are within the proximity of thevessel but that are separated and isolated from the fluid flow. Thisportion of the system has a durable encasement for any componentproximate to the vessel; however, the encasement allows the sensor toextend uninterruptedly into the fluid flow.

The system includes components similar to, or entirely distinct from,the fluid flow sensor to monitor properties of a fluid flow or any otherenvironment. The system comprises a non-intrusive acoustic sensor, anon-intrusive optical sensor, a rotational meter, a turbine/propeller, amoveable vane, a mechanical oscillator, a deformable diaphragm,vibrational viscometers, target flow meters, a vibration sensor, anaccelerometer, a displacement sensor, a barometer, and/or a fluid flowtemperature probe. The system is configured to process and leverage thevarious sensory inputs to ascertain certain fluid flow parameters. Allof the sensory readings are taken in real time and communicated tovarious system components as needed.

The system includes a user interface comprising a monitor/screenconfigured to render continuous information to a user. The system isequipped with programmable alarms/signals that leverage, at least inpart, the screens if any sensory input deviates from a presetvalue/range. The alarms/signals are also silent and communicated via thecomponents of the system. Notably, the system comprises a computingdevice, or hub device, in communication with two or more sensors,thereby providing for a single command station to monitor variousdisparate system components.

The system's hub device is communicatively coupled to one or moresensors and other system components. Communication is established viaBluetooth® brand of telecommunication or any other short wave radiosignal or optical communications technique. The system's hub devicestores sensory inputs, outputs sensory measurements (and the processingproducts therefor), outputs data to a user in real time, transmitscollected data to a remote device such as a server, or any combinationthereof. Major components of the system comprise onboard memory storageas well as wired, wireless, and/or optical transmitter(s) in order tostore and/or send real time output data.

Certain embodiments of systems and methods for continuous in situmonitoring of a fluid flow within a vessel involve an algorithmbeginning at time t. A fluid flow sensor is extended into the fluid flowand the fluid flow sensor takes readings at either predefined intervalsor intervals dependent on an external/internal condition. Thepairs/groupings of stress gauges of the fluid flow sensor takedeformation measurements of their respective internal surface segments.

Referring now to the drawings, wherein the showings are for purposes ofillustrating the various embodiments of the present disclosure only andnot for purposes of limiting the same, FIG. 1 illustrates a high levelfunctional block diagram of an exemplary architecture of a system 10 forcontinuous in situ monitoring of a fluid flow within a vessel. A vesselproximity 195 includes a hub component 99 in the form of a computingdevice and a sensor package 125. The vessel proximity 195 envisions asensor package 125 in wireless communication via a link 190A with a hubcomponent 99 that is in the vicinity of a vessel with a fluid flow. Forexample, a vessel may have a sensor package 125 attached such that thesensor 159 of the sensor package traverses the walls of the vessel andextends, at least partially, into the fluid flow. The computing device99 is one example of a hub component that is positioned proximate to thevessel but that is also communicatively coupled to the sensor package125, as well as multiple other sensor packages. The plurality of sensorpackages are engaged with the vessel at various positions along thelength of the vessel and, thus, within the vessel proximity 195. Anotherexample of the hub component 99 and the sensor package 125 being withinthe vessel proximity 195 include the sensor package 125 being engagedwith the vessel and the hub component 99 being monitored by a nearbyuser.

Notably, although the FIG. 1 illustration depicts a sensor package 125and a hub component 99 within a common vessel proximity 195, it isunderstood that not all embodiments of the system require a hubcomponent 99 to be within a vessel proximity. That is, it is envisionedthat certain functionalities of the system are implemented via a remotecomputing device such as a computation server 118. In such embodiments,the sensor package 125 communicates with the computation server 118 viaa communications network 191 without need for a hub device 99. In otherembodiments, a sensor package 125 communicates with either or both ofthe computation server 118 and the hub component 99. Similarly, in someembodiments, the hub component 99 transmits data to and/or fromcomputation server 118 via link 190B which is implemented over thecommunications network 191.

In the FIG. 1 embodiment, the sensor package 125 is shown to include apower supply 188B, a communications module 116B (for establishingcommunications with either or both of hub component 99 and computationserver 118 via communications network 191), a processor 110B, and amemory 112B. The sensor package 125 also includes a plurality of sensors159 (which themselves include any combination of a fluid flow sensor, anon-intrusive acoustic sensor, a non-intrusive optical sensor, arotational meter, a turbine/propeller, a moveable vane, a mechanicaloscillator, a deformable diaphragm, vibrational viscometers, target flowmeters, a vibration sensor, an accelerometer, a displacement sensor, abarometer, and/or a fluid flow temperature probe, etc.), a monitormodule 114 (for monitoring the sensors 159), and a computation module113B (for processing the sensory data from the sensors 159).

Similar to the sensor package 125, the hub component 99 includes acommunications module 116A (for transmitting and/or receivingcommunications over the network 191 from the computation server 118and/or the sensor package 125), a processor 110A, a memory 112A, and acomputation module 113A. The hub component 99 also includes a display132 for rendering one or more outputs to a user. The computation server118 as includes a computation module 113C.

Notably, not all of the components depicted in the FIG. 1 illustrationare required in all system embodiments. That is, it is envisioned, forexample, that a certain embodiment includes a single computation module113A in a hub component while another embodiment includes computationmodules 113 in each of the sensor package 125, the hub component 99, andthe computation server 118. As such, it is understood from the FIG. 1illustration that all of certain modules, or a portion of a certainmodule, may or may not reside in a certain component of the system.

As described above, the sensor package 125 is in proximity and engagedwith a vessel such that the sensors 159 monitor their respective fluidflow and/or non-fluid flow properties/characteristics. Notably, althoughnot shown in the FIG. 1 illustration, it is envisioned that certainsensors, such as ambient temperature sensors, may reside within hubcomponent 99. The monitor module 114 monitors/interrogates the sensorsand forwards the collected data to the computation module 113B accordingto instructions dictated by the computation module 113B and/or the othersystem 10 components. For example, the computation module 113B receivesdeformation measurement readings from the sensors 159 (specifically thefluid flow sensor) and, based at least in part on the deformationmeasurements, computes certain fluid flow parameters.

The data generated by the sensors 159, collected by the monitor module114 and managed by the computation module 113B, are be stored locally inthe memory 112B of the sensor package 125 and/or transmitted to the hubcomponent 99 and/or the computation server 118. Once received by the hubcomponent 99 and/or the computation server 118, the computation modules113A, 113C may use the measurement data to compute/process/leverage theinformation. Notably, it is envisioned that certain system embodimentsare comprised completely within a sensor package 125, while other systemembodiments comprise a minimalist sensor package 125 including onlythose components needed for collecting measurements and transmitting themeasurements to other components in the system 10.

In certain system embodiments, data generated by the sensors 159 andtransmitted to the computation server 118 are stored in a database 120for later download and utilization. Similarly, it is envisioned thateither or both of the sensor package 125 and the hub component 99include a computation database 120 in their respective memories 112.

The exemplary embodiments of the hub component 99 and the sensor package125 envision remote communication, real-time software updates, extendeddata storage, etc., and may be leveraged in various configurations bythe users of system 10. Advantageously, embodiments of the hubcomponents 99 and/or the sensor packages 125 are configured forcommunication via a computer system as depicted in FIG. 1. This involvesleveraging communications networks 191 including, but not limited tocellular networks, PSTNs, cable networks, Wi-Fi® brand ofcommunications, and the Internet for, among other things, softwareupgrades, content updates, database queries, data transmission, etc.Other data communications means that are use in connection with the hubcomponent 99 and/or the sensor package 125, and accessible via theInternet or other networked system, will occur to one having ordinaryskill in the art.

The illustrated computer system 10 comprises a computation server 118that is communicatively coupled to a network 191 comprising any or allof a wide area network (“WAN”), a local area network (“LAN”), theInternet, or a combination of other types of networks. It is understoodthat the term server 118 refers to a single server system or multiplesystems or multiple servers. The server 118 is coupled to a computationdatabase 120, as described above. The computation database 120 storesvarious records related to, but not limited to, historical sensorreading data, computation algorithms and methods, filters/rulesalgorithms, user preferences, previously calculated fluid flowparameters, trends, etc.

The computation server 118 is communicatively coupled to the network191. The computation server 118 communicates through the network 130with various different hub components 99 and sensor packages 125associated with the system 10. Each hub component 99 and/or each sensorpackage 125 runs/executes network communication software orfunctionalities to access the computation server 118 and its varioussystem applications (including computation module 113C). The hubcomponent 99 or the sensor package 125, as well as other componentswithin system 10 (such as, but not limited to, a wireless router), arecommunicatively coupled to the network 191 by various types ofcommunication links 145. These communication links 145 may comprisewired as well as wireless and/or optical links. The communication links145 allow the hub component 99 or the sensor package 125 to establishvirtual links 190 with the server 118 and/or each other. While a virtuallink 190B, for example, is depicted between the server 118 and the hubdevice 99, an actual wired/wireless/optical link 145 may exist betweenthe server 118 and the hub device 99. It is envisioned that this link145 is used to relay data to the computation server 118 from the hubcomponent 99 and/or the sensor package 125 as a uni-directionalcommunications channel or as a bi-directional communications channel.

It is envisioned that the display 132 comprises any type of displaydevice known to one having ordinary skill in the art such as a liquidcrystal display (“LCD”), a plasma display, an organic light-emittingdiode (“OLED”) display, a touch activated display, and a cathode raytube (“CRT”) display, a brail display, an LED bank, and a segmenteddisplay. The hub component 99 executes/runs or interface with amultimedia platform that is part of a plug-in for a network browser, forexample.

The communications module 116 comprises wireless communication hardwaresuch as, but not limited to, a Wi-Fi_(—)33® brand of communications cardor near field communications (NFC) card for interfacing with the system10 components. Further, the communications module 116 includes acellular radio transceiver to transmit collected sensory data as well asother information to other components of the system. One having ordinaryskill in the art recognizes that a communications module 116 includesapplication program interfaces to processor 110 as is understood by onehaving ordinary skill in the art.

A fluid flow controller 300 is also a component of the system 10. Itleverages the communications network 191 to communicate with the variousother components of the system 10. The fluid flow controller 300comprises a computation module 113D with all of the same features,aspects and functionalities described herein. The fluid flow controller300 represents a portion of a fluid flow process system (not depicted)that regulates the fluid flow properties in the vessel, i.e., fluidvelocity, mixture composition, etc. One having ordinary skill in the artunderstands that the fluid flow controller is an intermediate componentin a complex fluid flow process system that comprises valves, ports,pumps, motors, grates, sieves, etc. The fluid flow controller 300, basedat least on computation module 113D, is configured to receive sensorydata transmitted across the components of the system 10, analyze thatdata to compute various fluid flow parameters and leverage/transmit thatinformation to other components of a fluid flow process system such thatthe fluid flow is regulated/modified/corrected by the fluid flow processsystem. The fluid flow controller 300 is therefore an intermediatecomponent in a complex mechanical and computational regulatory systemfor the fluid flow in the vessel.

FIGS. 2A and 2B are side cross-sectional views of one embodiment of aspherical fluid flow sensor 100; specifically, the FIG. 2A view is of anundeformed sensor 100 and the FIG. 2B view is of a deformed sensor 100within a fluid flow 109. The sensor 100 comprises a base 101 and a bodymember 102 connected to the base 101 via a rigid stalk 103. The stalk103 is firmly attached at one end to the base 101 and its second end isfused with the body member 102 in a manner that prevents fluid frompenetrating inside the cavity of the stalk 103 and the body member 102.It is envisioned that the stalk is resistant to deformation to ensurethat all fluid flow drag effects are reflected primarily in themorphology of body member 102.

Base 101 is positioned through a wall 104 of a structural componentholding the fluid flow, such as a vessel or pipe, whose parameters areto be monitored. As such, the spherical member 102 is in contact withthe fluid flow. Two optical FGB strain gauges 105, 106 are affixed tothe inner surface of the body member 102 to monitor the deformation oftheir respective internal surface segments. The gauges 105, 106 areaffixed using an adhesive; however, any means for coupling the gauges105, 106 to the inner surface is envisioned, e.g., welding, mechanicalfasteners, chemical bonding, electromagnetic physical attraction(magnetism).

Optical fibers 107, 108 communicatively couple the strain gauges 105,106, respectively, to an appropriate optical interrogator (not depicted)that collects information about the length of each gauge. It isenvisioned that an optical interrogator, as is understood by one havingordinary skill in the art, is one embodiment of a monitor module 114 ofFIG. 1.

In FIG. 2A, the shape of the body member 102 is spherical whenundeformed and when not under the influence of the drag of the fluidflow 109. FIG. 2B depicts the body member 102 when deformed by the fluidflow 109. Under the influence of the fluid flow 109 (specifically thedrag of the fluid flow 109 as compared to the pressure of the fluid flow109) the body member 102 becomes elongated along the direction of thefluid flow 109. The body member 102 deforms to become more streamlined,i.e., the morphology of the body member 102 changes based, at least inpart, on the friction/drag of the fluid flow 109. In the morphologydepicted by FIG. 2B, the internal surface segment corresponding to thestrain gauges 105, 106 stretch (experience less compression) as comparedto their undisturbed state as depicted in FIG. 2A. It is, of courseenvisioned, that the internal surface segment corresponding to thestrain gauges 105, 106 will compress under other environmentalcircumstances.

The more streamlined morphology of the body member 102 results inchanges in the physical state of various external surface segments,which are ultimately translated by corresponding internal surfacesegments of the body member 102. The strain gauges 105, 106 areconsequently configured to measure the deformation of certain internalsurface segments and to communicate the deformation measurements toother components of the system 10.

FIGS. 3A and 3B are side cross-sectional views of one embodiment of acylindrical fluid flow sensor 200; specifically, the FIG. 3A view is ofan undeformed sensor 200 and the FIG. 3B view is of a deformed sensor200 within a fluid flow 209. The sensor 200 comprises a base 201 and abody member 202. The body member 202 is fused, at one end, to the base201 and, at the second end, is sealed such that the internal cavity ofthe body member 202 is isolated from the fluid flow 209. It isenvisioned that the body member 202 is one contiguous piece or isconstructed from various component pieces; however, regardless of itsfabrication, the resulting hollow body member 202 is one cohesivecomponent with a substantially flush external surface area. This ensuresthat any seams between the component pieces of the hollow body member202 are minimized to avoid any mechanical failures/fissures/leaks intothe internal cavity of the hollow body member 202.

The base 201 is positioned through a wall 203 of a structural componentholding the fluid flow 209. As such, the external surface of the bodymember 202 is in contact with the fluid. One having ordinary skill inthe art understands that the base 201 is engaged with the wall 203 suchthat the fluid containment function of the vessel is maintained. It isenvisioned that the base 201 is configured such that any leaks betweenthe junction of the base 201 and the wall 203 do not penetrate theinternal cavity of the body member 202 and/or contact the components ofthe system 10 positioned within the internal cavity or proximate to thevessel (including any means for communicating information betweencomponents, e.g., any optical fibers).

Two optical FGB strain gauges 204, 205 are communicatively coupled tothe optical fibers 206, 207 respectively. The optical FGB strain gauges204, 205 are engaged to internal surface segments on opposite internalsurfaces (i.e., the optical FGB strain gauges 204, 205 lie on the sameaxial traversing plane of the body member 202). Optical fibers 206, 207communicatively couple strain gauges 204, 205 to an optical interrogator(not depicted) that obtains deformation measurements from eachcorrelated pair/group of internal surface segments.

FIG. 3A depicts an undeformed body member 202, and FIG. 3B depicts thedeformation of the body member 202 in a fluid flow 209. Assuming thatthe fluid flow force is uniform along the length of the body member 202,a deformation of the body member 202 is due to uniformly distributedload ω (N/m) defined by:

$\begin{matrix}{y = {\frac{\omega \; x^{2}}{24{El}}\left( {x^{2} + {6l^{2}} - {4{lx}}} \right)}} & {{Equation}\mspace{14mu} 1}\end{matrix}$

where x is the coordinate along the axis of the body member 202 (thefixed end corresponds to x=0), y is the axis deformation at coordinatex, E is the Young's modulus of the material of the body member 202, I isthe momentum of inertia of the body member 202, which for asubstantially hollow cylindrical beam is defined by:

$\begin{matrix}{I = {\frac{\pi}{4}\left( {r_{o}^{4} - r_{i}^{4}} \right)}} & {{Equation}\mspace{14mu} 2}\end{matrix}$

where r_(o) is the outer radius and r_(i) is the inner radius, l is thelength of the beam. The deflection of the tip of the beam is found via:

$\begin{matrix}{\delta_{\max} = \frac{\omega \; l^{4}}{8{El}}} & {{Equation}\mspace{14mu} 3}\end{matrix}$

Therefore, the deformation measurements of the body member 202,specifically, of the internal surface segments that deform to producethe deformed body member 202 illustrated in FIG. 3B, carry informationabout the drag exerted by the fluid flow 209 on the body member 202.Assuming no temperature effect, when the body member 202 deforms, theupstream strain gauge 204 stretches (increases its length by an extralength α) and the downstream strain gauge 205 compresses (decreases itslength by the same distance α). The strain gauges 204, 205 are affixedin a certain position x_(o) along the length of the length of bodymember 202 where the relative change of its length,

$\frac{\Delta \; L}{L}(x)$

(L is the length of the strain gage), is at a maximum. For a uniformcylinder, this position is at the middle point (that is x₀=0.5·l).

Both the upstream and the downstream internal surface segments of thebody member 202 also stretch or compress due to thermal expansion orcontraction if the temperature of the body member 202 varies. Therefore,deformation measurements from the respective strain gauges 204, 205 alsocontain information about the effects of the thermalexpansion/contraction based, at least in part, on the fluid flow. If thechange in the length of the internal surface segments due to thermalexpansion/contraction is β, the total change in the length of theinternal surface segment associated with the strain gauge 204 isγ_(u)=α+β and the length of the internal surface segment associated withthe strain gauge 205 is γ_(d)=−α+β. Therefore, independently measuringγ_(u) and γ_(d) allows the system 10 to separately compute the stretchdue to the drag of the fluid flow (by computing the differential signalfrom the strain gauges 204, 205 [(γ_(d)−γ_(u))/2]) and the stretch dueto thermal expansion (by computing the average signal from the straingauges 204, 205 [(γ_(d)+γ_(u))/2]).

The differential signal (γ_(d)−γ_(u))/2=α is proportional to deflectionδ_(max), which is proportional to the drag by the fluid flow 209 on thebody member 202. The average signal (γ_(d)+γ_(u))/2=β is proportional tothe thermal expansion/contractions of the body member 202. Computingspecific parameters for the force and the temperature effects of thefluid flow 209 on the body member 202, and corresponding them to aparticular set of measurables γ_(d) and γ_(u), is possible based, atleast in part, on modeling or calibration, as is understood by onehaving ordinary skill in the art.

It is envisioned that the system 10 compensates, in its computations,for the thermal expansion/contraction of the body member 202 byleveraging the sensory measurements from at least one temperature sensorpositioned in the immediate vicinity of the body member 202. Such areference sensor provides real-time temperature measurements of thefluid flow, which is used to compute the expansion/contraction due totemperature change, β, and/or the expansion/contraction due to fluidflow force, α. This type of algorithmic analysis is understood by onehaving ordinary skill in the art.

Returning to the explanation of FIG. 3B, the force acting on the bodymember 202 in the fluid flow 209 is defined by:

$\begin{matrix}{F = {\frac{C_{d}}{2}A\; \rho \; v^{2}}} & {{Equation}\mspace{14mu} 4}\end{matrix}$

where C_(d) is a drag coefficient of a cylinder, A=2r_(o)l defines thecross section of the cylinder, ρ is the fluid density, ν is the flowvelocity, C_(d) depends on the Reynolds number,

$\begin{matrix}{{Re}_{d} = \frac{2r_{o}v\; \rho}{\mu}} & \left( {{FIG}.\mspace{11mu} 4} \right)\end{matrix}$

and μ is the dynamic viscosity. By knowing the fluid viscosity anddensity, the system 10 has the information necessary to compute thefluid velocity and volumetric flow rate. Inversely, by knowing the flowrate of the fluid flow, the system 10 has the information to compute thefluid viscosity and the density. Therefore, the sensor 200 allows forthe system 10 to gather sensory measurements from which certain fluidflow parameters are computed, monitored and tracked over time.

FIG. 5 is a side cross-sectional view of one embodiment of a body memberfor a sensor 400; specifically, the FIG. 5 view is of a deformed sensor400 within a fluid flow (not depicted). The sensor 400 comprises a bodymember 401 with a mixed shape/geometry/configuration. The sensor 400includes a spherical portion 402 that facilitates the deformation of thebody member 401 based, at least in part, on the drag of the fluid flow.Therefore, the spherical portion 402 affords the sensor 400 withadditional external surface area on which the drag of the fluid flow canact.

The spherical portion 402 is depicted as having no internal cavity;however, it is envisioned that the spherical portion 402 is its owndiscrete body member (such as the body member 101 of FIGS. 2A-2B). Thistype of configuration allows the external surface of the body member 401to deform differently along the cylindrical portion (essentially, acylindrical hollow body member such as the body member 202 of FIGS.3A-3B) as compared to the spherical portion 402. One having ordinaryskill in the art understands that the differences between a sphericalbody member (as described herein) and a cylindrical body member (asdescribed herein) affords the system 10 with different sources ofdeformation measurements, which can provide different and/orcomplimentary information about the parameters of the fluid flow.

FIG. 6 is a graphical presentation of a fluid flow's force over time ascomputed by the system 10 based, at least in part, on the deformationmeasurement signals from a fluid flow sensor. As described herein, in aparticulate fluid flow, the body member of a fluid flow sensor not onlyexperiences deformation based, at least in part, on the drag of thefluid flow but also based on the recurring impacts of particles/particleagglomerates in the fluid flow. In such occasions, the fluid flow sensorprovides measurements that are computed by the system 10 into a pulsedresponse as depicted in FIG. 6.

More specifically, FIG. 6 illustrates the force of a particulate fluidflow 209 as exerted on the body member 202 of the sensor 200 of FIGS.3A-3B. The body member 202 is primarily cylindrical and is extended intothe fluid flow in a high shear wet granulation (HSWG) process over aperiod of time with an acquisition rate of 500 Hz. As computed by thesystem 10, based at least in part on the deformation measurements fromthe strain gauges 204, 205 over the period of time, it is discernablethat the granulator blades exhibit a sin fit 501 frequency (oneembodiment of a parameter of the fluid flow) and that the fluid flow hasa plurality of force peaks 502. The plurality of force peaks 502(another embodiment of a parameter of the fluid flow) provideinformation about the force, time and frequency of impacts resultingfrom particles, particle agglomerates and/or consolidated granules inthe fluid flow. The system 10 leverages/processes this information tocompute the magnitudes of these peaks, which are indicative of the massand the density of the particulate fluid flow. One having ordinary skillin the art readily understands the algorithms necessary for thesecomputations.

FIG. 7 is a top cross-sectional view of the body member along line 7′-7′of FIGS. 3A-3B. In FIG. 7, the sensor 600 comprises a body member 601that is substantially cylindrical along its length. The sensor 600 alsocomprises two strain gauge pairs, the strain gauges 602, 603 and thestrain gauges 604, 605, engaged to the inner surface of the body member601. The strain gauges 602, 603 and the strain gauges 604, 605 takedeformation measurements at specific related internal surface segmentssuch that the plane formed by the strain gauges 602, 603 (indicated witha line x) is perpendicular to the plane formed by strain gauges 604, 605(indicated with a line y). It is envisioned that multiple other straingauge pairs/groupings exist along the length of the body member 601 andthat they can define various angles relative to the other strain gaugepairs/groupings.

As described herein, the two optical FGB strain gauges 204, 205 of FIGS.3A-3B are positioned in such a way that the direction of the fluid flow209 is parallel to the axial traversing plane on which the strain gaugepair lies. One having ordinary skill in the art understands that if thefluid flow 209 changes direction and if the sensor 200 only has the onepair/grouping of strain gauges depicted, the sensor 200 will onlyrespond to the projection of the force relative to this plane. If thatis the case, and if the magnitude and angular direction of the fluidflow is not otherwise known and/or sensed, the sensor 200 cannot providethe necessary deformation measurements to compute a desired fluid flowparameter.

This shortcoming is eliminated if the sensor 200 incorporates at leasttwo pairs of strain gauges working in perpendicular directions. FIG. 7depicts such an embodiment in the sensor 600. Therefore, at an arbitrarydirection of the flow fluid (not depicted), the strain gauges 602, 603take deformation measurements pertinent to the x vector component of thedesired fluid flow parameter, and the strain gauges 604, 605 takedeformation measurements pertinent to the y vector component of thedesired fluid flow parameter. One having ordinary skill in the artreadily understands the algorithms necessary for grouping and processingthe deformation measurements and for computing a composite fluid flowparameter based on the derived vector components.

FIG. 8 is side cross-sectional view of an embodiment of a plurality ofdeformed cylindrical fluid flow sensors 700 similar to the fluid flowsensor 200 of FIGS. 3A-3B. The plurality of fluid flow sensors 700 areassembled in a series along the construction wall 701 of a vessel;however, the plurality of fluid flow sensors 700 are not limited to whatis depicted in FIG. 8. One having ordinary skill in the art understandsthat the individual fluid flow sensors 700 are configured to bepositioned along numerous paths of the wall 701. Moreover, theindividual fluid flow sensors 700 are configured to be separated bylarge distances and to extend different lengths into the fluid flow 703.Moreover, the individual fluid flow sensors 700 each contribute sensoryinformation to a hub component 99 and/or a computation server 118 forprocessing, as described herein. Moreover, the individual fluid flowsensors 700 are part of the same sensor package 125 or part of discretesensory packages 125.

FIG. 9 illustrates a high level functional block diagram of a fluid flowforce measurement system 809 for monitoring and control of an industrialprocess. One or multiple sensor(s) 100, 200 are extended into a fluidflow within a vessel. An interrogator 800 is communicatively coupled tothe sensors 100, 200 via optical fibers 107, 108, 206, 207. The FBGstrain gauges 105, 106, 204, 205 are interrogated with light from alight source of variable optical spectrum 801. The light source ofvariable optical spectrum 801 comprises a tunable laser and iscontrolled, at least in part, by a light source control unit 802.

The light reflected off of the specific internal surface segments of thestrain gauges 105, 106, 204, 205 are communicated back to theinterrogator 800 via the optical fibers 107, 108, 206, 207, as isreadily understood in the art. More specifically, the light reflectedcontains information about the deformation of the internal surfacesegments and is indicative of the fluid flow parameters acting on theflexible hollow body member 102, 202. One or multiple optical detectors803 of the interrogator 800 receive the light reflected off of thespecific internal surface segments. Signal/data outputs from the opticaldetectors 803 are conditioned by a signal conditioner 804 and digitizedby a signal processing unit 805.

The interrogator 800 is controlled by a computational module thatcomprises a processor 806, a memory 807, and a human interface device806. The computational module, being preloaded with appropriatesoftware, begins to, at least in part, process the deformationmeasurements, e.g., groups them, labels them, correlates them.Furthermore, the interrogator 800 additionally comprises a communicationmodel 810 through which the interrogator 800 delivers the rawdeformation measurements and/or the processed data/signals to a remotemonitoring and control server 811. This involves a communication network812.

Using a computation database 813 associated with the monitoring andcontrol server 811, the monitoring and control server 811 analyzes datareceived from the interrogator 800 and, according to predeterminedalgorithm or user interferences, sends a control command/signal to theprocess control unit 814. The process control unit 814 then leveragesthat command/signal to introduce changes into the industrial process.For example, the process control unit 814 transmits control commandsthat change the rotation speed of a high-shear wet granulator involvedin the industrial process. Moreover, the process control unit 814transmits control commands that add a specified quantity of a chemicalin the fluid flow. Based on certain feedback and control systems, theserver 811 then changes the measurement regime/technique by modifyingthe software within the interrogator 800.

FIG. 10 is a logical flowchart illustrating a method of continuous insitu monitoring of a fluid flow within a vessel. Beginning at block 505,a computation module determines the start time of a monitoring period.At block 510, separate deformation measurement(s) from the individualstrain gauge(s) of a fluid flow sensor in a sensor package are monitoredby a monitoring module. At block 515, a monitor module and/or acomputation module process the separate deformation measurement(s) fromthe individual strain gauge(s) to determine if a fluid flow parameter(s)deviates for a target. As is understood by one having ordinary skill inthe art, this may comprise running regressive and/or statisticalanalysis of all past deformation measurement(s) and all presentdeformation measurement(s). Moreover, this may involve buffering andadjustments when necessary. Moreover, the targets may be a specificvalue, a range or a statistic deviation from a certain computed trend,as is understood by one having ordinary skill in the art.

Two deviations in the method occur if the computed fluid flowparameter(s) do(es) deviate from a target. If the computed fluid flowparameter(s) do(es) deviate from a target, then the method continues onto block 520 wherein an output alarm signal is communicated by themonitor module and/or the computation module. One having ordinary skillin the art understands that that output alarm signal may take the formof a visual alert to a user through the user interfaces describedherein. One having ordinary skill in the art also understands that thatoutput alarm signal may be in the background of the system and functionas a silent signal that influences/affects the system's operation(s).Once the alarm signal is outputted, the method continues on to block525.

If the computed fluid flow parameter(s) do(es) not deviate from atarget, then, at block 525, separate deformation measurement(s) from theindividual strain gauge(s) of the fluid flow sensor in the sensorpackage are continued to be monitored by the monitoring module. At block530, the monitor module and/or the computation module process theseparate deformation measurement(s) from the individual strain gauge(s)to compute a fluid flow parameter(s) and to output the fluid flowparameter(s) to the components of the system.

Next, at block 535, the computation module determines the end time ofthe monitoring period. Next, at block 540, the computation module storesthe separate deformation measurement(s) from the individual straingauge(s) and the computed fluid flow parameter(s). The computationmodule also stores any statistical analysis of the discrete fluid flowparameter(s) over the course of the monitoring period.

FIG. 11 is a logical flowchart illustrating another method of continuousin situ monitoring of a fluid flow within a vessel. Beginning at block605, separate deformation measurement(s) from the individual straingauge(s) of a body member of a fluid flow sensor are received by amonitoring module. At block 610, a computation module analyzes theseparate deformation measurement(s) from the individual strain gauge(s).

At block 615, a computation module groups the related measurement(s)from the individual strain gauge(s). One having ordinary skill in theart understands that this may involve information about the relativelocation of the strain gauges and which internal surface segments theyare reading. This may also involve the monitoring module transmittinginformation about the relationship between the strain gauges, i.e.,whether they are part of a particular pre-established pair/grouping,whether they are in direct alignment with a sensed fluid flow direction,or whether they are at a particular angle relative to the fluid flow.This also may involve the monitoring module transmitting other relatedsensory data from other non-strain gauge sensors.

Next, at block 620, a computation module compares the relatedmeasurement(s) from the individual strain gauge(s) within theestablished grouping(s). One having ordinary skill in the artunderstands that this may involve processing historical informationabout past related measurements from the individual strain gauges todetermine if the present measurement(s) is/are likely to be inaccurateor imprecise as compared to the others in the established grouping. Thismay involve comparing the measurement(s) within the group to determineif the present measurement(s) is/are likely to be inaccurate orimprecise. This may also involve statistical or regressive analysis, asis understood by one having ordinary skill in the art.

Next, at block 625, a computation module computes difference(s) betweenthe related measurement(s) within the established grouping(s). Onehaving ordinary skill in the art understands that this may be as simplea subtracting the related measurements within the established groupings.It may also involve more complicated methods of eliminating possibleoutliers and/or misgrouped measurements. It may also involve statisticalanalysis that results in an aggregate difference between themeasurement(s) with in the established grouping(s).

Next, at block 630, the difference(s) between the related measurement(s)within the established grouping(s) is output to other system components.One having ordinary skill in the art understands this information can beuseful for the computation of a fluid flow parameter(s), for computationof the differential signal between related strain gauges and for thecomputation of the average signal between related strain gauges.

Next, at block 635, further measurement(s) from the individual straingauge(s) of a body member of a fluid flow sensor are received by themonitoring module. At block 640, the computation module then againgroups the related measurement(s) from the individual strain gauge(s).At block 645, two deviations in the method occur if the groupings ofrelated measurement(s) from the individual strain gauge(s) change fromhow they were grouped at block 615. If the groupings of relatedmeasurement(s) from the individual strain gauge(s) would not change fromhow they were grouped at block 615, then the method reverts to block630.

If the groupings of related measurement(s) from the individual straingauge(s) would change from how they were grouped at block 615, then, atblock 650, the computation module compares the related measurement(s)from the individual strain gauge(s) within the newly establishedgrouping(s). One having ordinary skill in the art understands that thismay involve processing historical information about past comparisonsbetween the related measurements from the individual strain gauges todetermine if the present grouping(s) is/are likely to be inaccurately orimprecisely formed.

Next, at block 655, a computation module computes difference(s) betweenthe related measurement(s) within the newly established grouping(s).Next, at block 660, the difference(s) between the related measurement(s)within the newly established grouping(s) is output to other systemcomponents.

FIG. 12 is a logical flowchart illustrating another method of continuousin situ monitoring of a fluid flow within a vessel. The method 900 isessentially identical to the method 600 described above; however, acomputation module additionally identifies preferred groupings of theestablished grouping(s) of block 920. One having ordinary skill in theart understands that the established groupings may be identified aspreferred groupings depending on the specific shape and configuration ofthe body member of the sensor. It may also depend on the magnitude,direction and angle of the fluid flow as it interacts with the sensor,and how the potential preferred groupings relate to the fluid flow,i.e., whether all the strain gauges producing the measurements withinthe grouping are substantially parallel or substantially perpendicularto the fluid flow. For example, in FIG. 7, the grouping containing thedeformation measurements from the strain gauges 602, 603 and thegrouping containing the deformation measurements from the strain gauges604, 605 may both be identified as preferred groupings because theyrepresent groups of strain gauges that are parallel and perpendicular tothe fluid flow 209, respectively.

Next, at block 925, the computation module compares the relatedmeasurement(s) from the individual strain gauge(s) within the identifiedpreferred groupings. Next, at block 930, a computation module computesvector components of a fluid flow parameter based, at least in part, onthe deformation measurement within the identified preferred groupings.One having ordinary skill in the art understands that this may involve acomputation module computing the difference(s) between the relatedmeasurement(s) within the identified preferred groupings, as describedin block 625 of method 600.

Next, at block 935, the computed vector components of a fluid flowparameter are output to other system components. One having ordinaryskill in the art understands this information can be useful for thecomputation of a fluid flow parameter(s), for computation of thedifferential signal between related strain gauges and for thecomputation of the average signal between related strain gauges.

Next, at block 940, further measurement(s) from the individual straingauge(s) of a body member of a fluid flow sensor are received by themonitoring module. At block 945, the computation module then againgroups the related measurement(s) from the individual strain gauge(s).At block 950, two deviations in the method occur if the identifiedpreferred groupings would change from those identified at block 920. Ifthe identified preferred groupings would not change from thoseidentified at block 920, then the method reverts to block 925.

If the identified preferred groupings would change from those identifiedat block 920, then, at block 955, the computation module newlyidentifies preferred groupings of the established grouping(s) from block945. One having ordinary skill in the art understands that theestablished groupings may be newly identified as preferred groupingsdepending on the magnitude, direction or angle of the fluid flow as itinteracts with the sensor.

Next, at block 960, the computation module compares the relatedmeasurement(s) from the individual strain gauge(s) within the newlyidentified preferred groupings. Next, at block 965, the computationmodule computes vector components of a fluid flow parameter based, atleast in part, on the deformation measurement within the newlyidentified preferred groupings. Next, at block 970, the computed vectorcomponents of a fluid flow parameter are output to other systemcomponents.

FIG. 13 is a schematic diagram illustrating an exemplary softwarearchitecture 1000 for devices, systems and method of continuous in situmonitoring of a fluid flow within a vessel. As illustrated in FIG. 13,the CPU or digital signal processor 110 is coupled to the memory 112 viamain bus 211. The memory 112 may reside within a hub component 99, asensor package 125 or a combination thereof. Similarly, it will beunderstood that the computation module 113 and the CPU 110 may residewithin a hub component 99, a sensor package 125 or a combinationthereof.

The CPU 110, as noted above, is a multiple-core processor having N coreprocessors. That is, the CPU 110 includes a first core 222, a secondcore 224, and an N^(th) core 230. As is known to one of ordinary skillin the art, each of the first core 222, the second core 224 and theN^(th) core 230 are available for supporting a dedicated application orprogram. Alternatively, one or more applications or programs may bedistributed for processing across two or more of the available cores.

The CPU 110 may receive commands from the computation module(s) 113 thatmay comprise software and/or hardware. If embodied as software, themodule(s) 113 comprise instructions that are executed by the CPU 110that issues commands to other application programs being executed by theCPU 110 and other processors.

The first core 222, the second core 224 through to the N^(th) core 230of the CPU 110 may be integrated on a single integrated circuit die, orthey may be integrated or coupled on separate dies in a multiple-circuitpackage. Designers may couple the first core 222, the second core 224through to the N^(th) core 230 via one or more shared caches and theymay implement message or instruction passing via network topologies suchas bus, ring, mesh, and crossbar topologies.

Bus 211 may include multiple communication paths via one or more wired,wireless or optical connections, as is known in the art. The bus 211 mayhave additional elements, which are omitted for simplicity, such ascontrollers, buffers (caches), drivers, repeaters, and receivers, toenable communications. Further, the bus 211 may include address,control, and/or data connections to enable appropriate communicationsamong the aforementioned components.

When the logic used by the components 99, 125 is implemented insoftware, as is shown in FIG. 13, it should be noted that one or more ofstartup logic 250, management logic 260, computation interface logic270, applications in application store 280 and portions of the filesystem 290 may be stored on any computer-readable medium for use by, orin connection with, any computer-related system or method. In thecontext of this document, a computer-readable medium is an electronic,magnetic, optical, or other physical device or means that can contain orstore a computer program and data for use by or in connection with acomputer-related system or method. The various logic elements and datastores may be embodied in any computer-readable medium for use by or inconnection with an instruction execution system, apparatus, or device,such as a computer-based system, processor-containing system, or othersystem that can fetch the instructions from the instruction executionsystem, apparatus, or device and execute the instructions. In thecontext of this document, a computer-readable medium can be any meansthat can store, communicate, propagate, or transport the program for useby or in connection with the instruction execution system, apparatus, ordevice.

The computer-readable medium can be, for example but not limited to, anelectronic, magnetic, optical, electromagnetic, infrared, orsemiconductor system, apparatus, device, or propagation medium. Morespecific examples (a non-exhaustive list) of the computer-readablemedium would include the following: an electrical connection(electronic) having one or more wires, a portable computer diskette(magnetic), a random-access memory (RAM) (electronic), a read-onlymemory (ROM) (electronic), an erasable programmable read-only memory(EPROM, EEPROM, or flash memory) (electronic), an optical fiber(optical), flash, and a portable compact disc read-only memory (CDROM)(optical). Note that the computer-readable medium could even be paper oranother suitable medium upon which the program is printed, as theprogram can be electronically captured, for instance via opticalscanning of the paper or other medium, then compiled, interpreted orotherwise processed in a suitable manner if necessary, and then storedin a computer memory.

In an alternative embodiment, where one or more of the startup logic250, management logic 260 and perhaps the computation interface logic270 are implemented in hardware, the various logic may be implementedwith any or a combination of the following technologies, which are eachwell known in the art: a discrete logic circuit(s) having logic gatesfor implementing logic functions upon data signals, an applicationspecific integrated circuit (ASIC) having appropriate combinationallogic gates, a programmable gate array(s) (PGA), a field programmablegate array (FPGA), etc.

The memory 112 is a non-volatile data storage device such as a flashmemory or a solid-state memory device. Although depicted as a singledevice, the memory 112 may be a distributed memory device with separatedata stores coupled to the digital signal processor 110 (or additionalprocessor cores).

The startup logic 250 includes one or more executable instructions forselectively identifying, loading, and executing a select program foridentifying accurate sensor readings and/or generating a computation offluid flow parameters. The startup logic 250 may identify, load andexecute a select computation program. An exemplary select program may befound in the program store 296 of the embedded file system 290. Theexemplary select program, when executed by one or more of the coreprocessors in the CPU 110 may operate in accordance with one or moresignals provided by the computation module 113 to identify accuratesensor readings and/or computer a fluid flow parameter.

The management logic 260 includes one or more executable instructionsfor terminating a system program on one or more of the respectiveprocessor cores, as well as selectively identifying, loading, andexecuting a more suitable replacement program. The management logic 260is arranged to perform these functions at run time or while thecomponent 99 is powered and in use by an operator of the device. Areplacement program, which may be customized by a user in some systemembodiments, may be found in the program store 296 of the embedded filesystem 290.

The interface logic 270 includes one or more executable instructions forpresenting, managing and interacting with external inputs to observe,configure, or otherwise update information stored in the embedded filesystem 290. In one embodiment, the interface logic 270 may operate inconjunction with manufacturer inputs received via the USB port 142.These inputs may include one or more programs to be deleted from oradded to the program store 296. Alternatively, the inputs may includeedits or changes to one or more of the programs in the program store296. Moreover, the inputs may identify one or more changes to, or entirereplacements of one or both of the startup logic 250 and the managementlogic 260. By way of example, the inputs may include a change to theweight of parameters used to generate a customized computationalgorithm.

The interface logic 270 enables a manufacturer to controllably configureand adjust an end user's experience under defined operating conditionson the component 99. When the memory 112 is a flash memory, one or moreof the startup logic 250, the management logic 260, the interface logic270, the application programs in the application store 280 orinformation in the embedded file system 290 may be edited, replaced, orotherwise modified. In some embodiments, the interface logic 270 maypermit an end user or operator of the component 99, 125 to search,locate, modify or replace the startup logic 250, the management logic260, applications in the application store 280 and information in theembedded file system 290. The operator may use the resulting interfaceto make changes that will be implemented upon the next startup of thecomponent 99, 125. Alternatively, the operator may use the resultinginterface to make changes that are implemented during run time.

The embedded file system 290 includes a hierarchically arrangedcomputation store 292. In this regard, the file system 290 may include areserved section of its total file system capacity for the storage ofinformation for the configuration and management of the variouscomputation equations and/or system algorithms used by the components99, 125.

Certain steps in the processes or process flows described in thisspecification naturally precede others for the invention to function asdescribed. However, the invention is not limited to the order of thesteps described if such order or sequence does not alter thefunctionality of the invention. That is, it is recognized that somesteps may be performed before, after, or parallel (substantiallysimultaneously with) other steps without departing from the scope andspirit of the invention. In some instances, certain steps may be omittedor not performed without departing from the invention. Further, wordssuch as “thereafter”, “then”, “next”, etc. are not intended to limit theorder of the steps. These words are simply used to guide the readerthrough the description of the exemplary method.

The various embodiments are provided by way of example and are notintended to limit the scope of the disclosure. The described embodimentscomprise different features, not all of which are required in allembodiments of the disclosure. Some embodiments of the presentdisclosure utilize only some of the features or possible combinations ofthe features. Variations of embodiments of the present disclosure thatare described, and embodiments of the present disclosure comprisingdifferent combinations of features as noted in the describedembodiments, will occur to persons with ordinary skill in the art. Itwill be appreciated by persons with ordinary skill in the art that thepresent disclosure is not limited by what has been particularly shownand described herein above. Rather the scope of the invention is definedby the appended claims.

What is claimed is:
 1. A system for continuous in situ monitoring of afluid flow within a vessel, the system comprising a sensor packagecomprising a sensor, the sensor comprising: a) a body member defining aninternal cavity such that the body member comprises a first externalsurface segment and a first internal surface segment, the body memberconfigured to extend into a fluid flow such that the internal cavity isisolated from the fluid flow and the first external surface segment isin contact with the fluid flow, the first external surface segment andthe first internal surface segment each, respectively, configured todeform based, at least in part, on the drag of the fluid flow, whereinthe first internal surface segment translates the deformation of thefirst external surface segment; and b) a first strain gauge positionedin the cavity of the body member and configured to measure thedeformation of the first internal surface segment, and communicate adeformation measurement of the first internal surface segment.
 2. Thesystem of claim 1, wherein the first internal surface segment defines aportion of the body member at which the drag of the fluid flow producesa maximum deformation in the body member.
 3. The system of claim 1,wherein the sensor package is configured to: a) analyze the deformationmeasurement of the first internal surface segment; and b) compute afluid flow parameter based, at least in part, on the deformationmeasurement of the first internal surface segment.
 4. The system ofclaim 3, wherein the fluid flow parameter is selected from the groupconsisting of a force, a temperature, a velocity, a flow rate, aviscosity, and a density of the fluid.
 5. The system of claim 3, whereinthe fluid flow is particulate and wherein the fluid flow parameter isselected from the group consisting of a mass and a density of a particlein the fluid flow.
 6. The system of claim 1, wherein the first straingauge is selected from the group consisting of an optical strain gauge,an electrical resistive strain gauge, and a semiconductor strain gauge.7. The system of claim 1, wherein the body member is spherical orcylindrical.
 8. A system for continuous in situ monitoring of a fluidflow within a vessel, the system comprising: a) a sensor comprising: b)a body member defining an internal cavity such that the body membercomprises a first external surface segment and a first internal surfacesegment, the body member configured to extend into a fluid flow suchthat the internal cavity is isolated from the fluid flow and the firstexternal surface segment is in contact with the fluid flow, the firstexternal surface segment and the first internal surface segment each,respectively, configured to deform based, at least in part, on the dragof the fluid flow, wherein the first internal surface segment translatesthe deformation of the first external surface segment; c) a firstoptical strain gauge positioned in the cavity of the body member andconfigured to measure the deformation of the first internal surfacesegment, and communicate the deformation measurement of the firstinternal surface segment via an optical signal; and d) an interrogatorcommunicatively coupled to the first optical strain gauge and configuredto receive an optical signal communicated by the optical strain gauge,and communicate the deformation measurement of the first internalsurface segment.
 9. The system of claim 8, the system additionallycomprising a controller communicatively coupled with the interrogatorand configured to: a) receive the deformation measurement of the firstinternal surface segment from the interrogator; b) analyze thedeformation measurement of the first internal surface segment; and c)compute a fluid flow parameter based, at least in part, on thedeformation measurement of the first internal surface segment.
 10. Thesystem of claim 1, wherein the body member additionally comprises: a) asecond external surface segment and a second internal surface segmenteach, respectively, configured to deform based, at least in part, on thedrag of the fluid flow, wherein the second internal surface segmenttranslates the deformation of the second external surface segment, andwherein the second and the first internal surface segments are alignedby a first plane; and b) a second strain gauge configured to measure thedeformation of the second internal surface segment.
 11. The system ofclaim 10, wherein the body member additionally comprises: a) a third anda fourth external surface segment and a third and a fourth internalsurface segment each, respectively, configured to deform based, at leastin part, on the drag of the fluid flow, wherein the third internalsurface segment translates the deformation of the third external surfacesegment, wherein the fourth internal surface segment translates thedeformation of the fourth external surface segment, wherein the thirdand the fourth internal surface segment are aligned by a second plane,and wherein the first and the second planes intersect and define anangle; b) a third strain gauge configured to measure the deformation ofthe third internal surface segment, and communicate a deformationmeasurement of the third internal surface segment; and c) a fourthstrain gauge configured to measure the deformation of the fourthinternal surface segment, and communicate a deformation measurement ofthe fourth internal surface segment.
 12. The system of claim 11, whereinthe sensor package is configured to: a) analyze the deformationmeasurements of the first, the second, the third and the fourth internalsurface segments; and b) compute a fluid flow parameter based, at leastin part, on the deformation measurements of the first, the second, thethird and the fourth internal surface segments and the angle defined bythe first and the second plane.
 13. The system of claim 12, wherein theangle defined by the first and the second plane is 90.0 degrees.
 14. Amethod of continuous in situ monitoring of a fluid flow within a vessel,the method comprising: a) extending a sensor, at least partially, into afluid flow within a vessel, the sensor comprising a body member and afirst strain gauge, the body member defining an internal cavity suchthat the body member comprises a first internal surface segment, theinternal cavity isolated from the fluid flow, the first strain gaugepositioned in the cavity; b) detecting, by the first strain gauge, adeformation of the first internal surface segment; c) transmitting, bythe first strain gauge, a deformation measurement of the first internalsurface segment; d) analyzing the deformation measurement of the firstinternal surface segment; and e) computing a fluid flow parameter based,at least in part, on the deformation measurement of the first internalsurface segment.
 15. The method of claim 14, the method additionallycomprising modifying the fluid flow.
 16. The method of claim 14, whereinthe sensor additionally comprises a second, a third, and a fourth straingauge and wherein the body member additionally comprises a second, athird, and a fourth internal surface, the first and the second internalsurface segments aligned by a first plane, the third and the fourthinternal surface segment aligned by a second plane, the first and thesecond planes intersecting and defining an angle, the methodadditionally comprising: f) detecting, by the second strain gauge, adeformation of the second internal surface segment; g) detecting, by thethird strain gauge, a deformation of the third internal surface segment;h) detecting, by the fourth strain gauge, a deformation of the fourthinternal surface segment; i) communicating a deformation measurement ofthe first, the second, the third and the fourth internal surfacesegment; and j) analyzing the deformation measurement of the second, thethird and the fourth internal surface segment; wherein computing thefluid flow parameter is additionally based, at least in part, on thedeformation measurements of the second, the third and the fourthinternal surface segment; and wherein computing the fluid flow parametercomprises: i) comparing the deformation measurements of the first andthe second internal surface segment; and ii) comparing the deformationmeasurements of the third and the fourth internal surface segment. 17.The method of claim 16, wherein computing the fluid flow parameteradditionally comprises: iii) calculating a difference between thedeformation measurements of the first and the second internal surfacesegment; iv) calculating a difference between the deformationmeasurements of the third and the fourth internal surface segment; andv) computing the fluid flow parameter, based at least in part, on thedifference between the deformation measurements of the first and thesecond internal surface segment and the difference between thedeformation measurements of the third and the fourth internal surfacesegment.
 18. The method of claim 16, wherein the fluid flow parameter isa vector and wherein computing the fluid flow parameter additionallycomprises iii) calculating a first vector component of the fluid flowparameter based, at least in part, on the angle defined by the first andthe second plane, and the deformation measurements of the first and thesecond internal surface segment; and iv) calculating a second vectorcomponent of the fluid flow parameter based, at least in part, on theangle defined by the first and the second plane, and the deformationmeasurements of the third and the fourth internal surface segment. 19.The method of claim 17, wherein computing the fluid flow parameteradditionally comprises: vi) computing the differential signal, from thefirst and the second strain gauge, based, at least in part, on thedifference between the deformation measurements of the first and thesecond internal surface segment; vii) computing the average signal, fromthe first and the second strain gauge, based, at least in part, on thedifference between the deformation measurements of the first and thesecond internal surface segment; and viii) computing the deformation ofthe first surface segment that is due to the drag of the fluid flowrelative to the thermal expansion of the first internal surface segment.20. The method of claim 19, wherein the sensor additionally comprises areference temperature sensor configured to sense the temperature of thefluid flow and wherein computing the fluid flow parameter additionallycomprises: ix) detecting, by the reference sensor, the temperature ofthe fluid flow; x) transmitting, by the reference sensor, a temperaturemeasurement of the fluid flow; and xi) computing the thermal expansionof the first internal surface segment that is due to the temperature ofthe fluid flow relative to the drag of the fluid flow.